Fabrication of a phase change material (PCM) integrated insulation

ABSTRACT

A method of making an insulated material comprises melting a phase change material to form liquid phase change material, combining the liquid phase change material with an insulating material, and forming a composite insulation material in response to the combining. The insulating material can be a porous material that comprises a plurality of pores, and the liquid phase change material is disposed in the plurality of pores. The phase change material can also be stored in a container and used as layer in an insulation system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority under 35U.S.C. § 120 to U.S. patent application Ser. No. 16/774,936, filed onJan. 28, 2020, entitled “FABRICATION OF A PHASE CHANGE MATERIAL (PCM)INTEGRATED INSULATION,” by Sheldon G. SHI, et al., which is incorporatedherein by reference in its entirety for all purposes.

STATEMENT REGARDING GOVERNMENTALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND

The building sector is a dominant energy consumer with around 40% shareof the overall energy consumption and accounts for approximately 39% ofthe greenhouse gas (GHG) emissions in the United States in 2014according to the U.S. Department of Energy. Highly insulated buildingenvelopes will help reduce the energy consumption from the heating,ventilation, and air conditioning (HVAC) system as well as the GHGemissions. The amount of insulation in building envelope is oftenlimited due to the high cost and space limitation.

Commercially available building insulation materials are typically ahigh cost for high R-value or low cost for low R-value. Moreover, manyconventional synthetic insulation materials, such as fiberglass, etc.,may have negative impacts on the environment. Cellulose insulations,which are processed from biomass are natural, biodegradable, lightweight, low cost, and environmental benign, and they are currentlycommercially available. However, they are usually present lower R-valuescompared to many synthetic materials, such as fiberglass, mineral wool,expanded polystyrene (EPS) foam, etc.

SUMMARY

In some embodiments, a method of making an insulated material comprisesmelting a phase change material to form liquid phase change material,combining the liquid phase change material with an insulating material,and forming a composite insulation material in response to thecombining. The insulating material can be a porous material thatcomprises a plurality of pores, and the liquid phase change material isdisposed in the plurality of pores.

In some embodiments, an insulated panel comprises an insulation layer,and a composite insulation material disposed on at least one surface ofthe insulation layer. The composite insulation material comprises aphase change material.

In some embodiments, a method of providing insulation comprises heatinga first side of a composite insulation material, melting at least aportion of the phase change material in response to the heating, andreducing heat transmission through the composite insulation materialfrom the first side to the second side based on the melting. Thecomposite insulation material comprises the first side and a secondside. The composite insulation material comprises a phase changematerial. The method can also include reducing the temperature on thefirst side of the composite insulation material, and solidifying thephase change material in response to reducing the temperature on thefirst side of the composite insulation material.

These and other features will be more clearly understood from thefollowing detailed description taken in conjunction with theaccompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure and theadvantages thereof, reference is now made to the following briefdescription, taken in connection with the accompanying drawings anddetailed description, wherein like reference numerals represent likeparts.

FIG. 1 is an illustration of the porous structure of woody fibers usefulin some embodiments.

FIG. 2 is an illustration of an embodiment of a microencapsulated PCMhoneycomb wallboard.

FIGS. 3A and 3B are schematic illustrations of encapsulated PCM(s)according to some embodiments.

FIG. 4 is an illustration of an embodiment of a construction of a wallintegrated with biomass/PCM based insulation for peak temperaturemitigation.

FIG. 5 is an illustration of a panel constructed using a compositeinsulation material having features according to some embodiments.

FIG. 6 illustrates a panel constructed using a composite insulationmaterial having a facing according to some embodiments.

FIG. 7A is a schematic view of a configuration of a composite insulationmaterial used in an insulation system according to an embodiment.

FIG. 7B is another schematic view of a configuration of a compositeinsulation material used in an insulation system according to anembodiment.

FIG. 7C is still another schematic view of a configuration of acomposite insulation material used in an insulation system according toan embodiment.

FIG. 7D is yet another schematic view of a configuration of a compositeinsulation material used in an insulation system according to anembodiment.

FIG. 7E is another schematic view of a configuration of a compositeinsulation material used in an insulation system according to anembodiment.

FIG. 8 is an illustration of the fabrication of the woody core/PCMcomposite according to some embodiments.

FIG. 9 is a graph illustrating the time ratio between discharging andcharging for 1-inch thickness composite insulation material vs. 6-inchPU foam (the base line).

FIG. 10 is a graph illustrating a comparison of time ratio betweendischarging and charging for various thicknesses of PU foam outside the1-inch composite insulation material layer

FIGS. 11A and 11B are illustrations showing that a composite insulationmaterial has the potential to save annual heating load by up to 16% andannual cooling power by up to 11% when applying the woody core-PCMcomposite to the ZOE research lab according to some embodiments.

FIG. 12 is an illustration of a wall internal surface temperature withrespect to various R-values of the insulation with/without PCM(s)embedded according to some embodiments.

FIG. 13 is an illustration of a non-limiting example showing of the heattransfer test section for the structure insulation panel.

DESCRIPTION

Disclosed herein are composite insulation materials, insulation systemsincorporating such materials, and their use in insulation systems. Thematerials use one or more phase change materials (PCM(s)) that canexperience a phase change at a desired temperature, which can generallybe selected to be near the temperature at which the composite insulationmaterials are being used. The phase change of the material can be usedto absorb and store heat at a temperature associated with the meltingpoint or melting point range. This effect can be used with the cyclicnature of heat and/or cold being applied to a building or regulatedenvironment to absorb heat during a peak temperature difference, andthen released at a time when the temperature differential across theinsulation is reduced. For example, the PCM(s) can be used to transitionfrom a solid to a liquid during the peak heat of the day, and thereconverted to a solid while being cooled later in the day or at nightwhen an air conditioner can operate more efficiently against a lowertemperature differential. This can provide significant energy savingsfor the buildings, maintain temperatures more effectively, and providehigher insulation values for comparative insulation thicknesses.

The insulated material as disclosed herein can include a phase changematerial (PCM) disposed within another material, such as the pores of aporous material, within an encapsulation within another materials,and/or as an encapsulated layer of PCM. The combination of one or morePCMs with another material can be referred to as a composite insulationmaterial herein. PCMs have phase change characteristics that can allowfor the storage and release of relatively large amount of thermal energy(latent heat of fusion) at a nearly constant temperature or over aselected temperature range. This characteristic of PCMs can enhance thethermal inertia and help mitigate peak loads in buildings. The PCM canbe stored in a porous material, an encapsulation, or a container thatcan serve to hold and retain the PCM in use in both the solid and liquidphases. The combination of the PCM within the materials can then serveas an insulation layer or a material within a structure. In someembodiments, the insulation layer can be part of an insulation panel orsystem. The properties of the composite insulation material can allowfor an increase in the insulating properties of an existing insulationlayer and/or allow the insulation to have a reduced thickness for thesame insulating properties, thereby improving the energy efficiency ofvarious insulated structures.

When the PCM(s) are used with a porous material, the porous material cancomprise any suitable material having a sufficient pore volume to retaina desired amount of the PCM(s). The porous material can comprise variousorganic materials such as biomass, polymers, polymeric foams, and thelike as well as inorganic materials such as mineral insulation, porousconcrete, and the like. In some embodiments, the porous material cancomprise various types of materials such as porous biomass, a porouspolymer, porous lignocellulosic fibers, porous polyurethane foams,porous expanded polystyrene, porous air-entrained concrete, porous rockwool, porous polyisocyanurate material, porous natural plant material,partially delignified lignocellulosic biomass, and combinations thereof.

The porous material can also comprise other types of materials such asPVC, honeycomb, plastic, stainless steel, and aluminum panels, any ofwhich can also be used to encapsulate PCM(s). The PCM(s) can also beincorporated into or impregnated within traditional insulationmaterials, such as polyurethane (PU) foam, fiberglass, cellulose fiber,Structural Insulated Panel (SIP), or combinations thereof eitherdirectly or through the use of an encapsulated PCM(s).

As an example, biomass, such as cellulosic fiber and woody core fromkenaf or hemp, has a porous structure, which the PCM can be depositedinto. FIG. 1 illustrates a micrograph of the porous structure of biomassas an example. The typical R-value of cellulosic insulation is around3-3.5 per inch thickness, which is lower than other conventionalsynthetic insulations (e.g., polyurethane (PU) foam's R-value is in therange of 5-7 per inch thickness). In some embodiments, the PCM(s) can beimpregnated into the pore structures of a porous material such ascellulose from biomass for insulation to enhance the thermal energystorage capacity of the insulation material due to the latent heat offusion. In some embodiments, the effective R-value (as defined herein)of the porous material having the PCM(s) impregnated therein can begreater than 7 per inch, greater than 8 per inch, greater than 9 perinch, or greater than 10 per inch.

In some embodiments, the PCM(s) can be incorporated into the porousmaterial during construction to form the pores within the material. Forexample, conventional construction materials, such as gypsum board,concrete, brick and plaster, can be used to retain the PCM(s), and insome embodiments, the PCM(s) can be disposed within the material as itis formed, as described in more detail herein.

The PCM(s) can be selected to have a melting point or meltingtemperature range at a temperature associated with the use of thecomposite insulation material. In some embodiments, the PCMs can beselected based on the building temperature range. PCMs with meltingtemperatures of 15-60° C. may be suitable for residential and/orcommercial structures that can be maintained at approximately roomtemperature. The PCMs can include, but are not limited to, inorganicsubstances (e.g., hydrated salts), organic substances (e.g., paraffinwax), and/or fatty acids. In some embodiments, the PCM(s) can comprises1-dodecanol, n-octadecane, polyethylene glycol 900, 1-tetradecanol,medicinal paraffin, a paraffin wax, paraffin RT60/RT58, biphenyl,CaCl₂.6H₂O, Na₂SO₄.10H₂O, Na₂CO₃.10H₂O, capric acid, lauric acid,myristic acid, palmitic acid, stearic acid, or combinations thereof. Insome embodiments, the PCM(s) can also include bio-based PCMs to improvethe energy performance of insulating materials. Non-limiting examples ofsuch PCMs can include, but are not limited to, organic-based materialsmade from plant-derived PCMs such as soy oil, palm oil, and the like.These materials have the property of being less flammable than someother organic PCMs, biodegradable, environmentally friendly, andrelatively low cost. Table 1 provides some exemplary PCMs that can beused for building applications.

TABLE 1 Melting Thermal Temp. Latent Heat of Conductivity Density PCM (°C.) Fusion (kJ/kg) (W/m · k) (kg/m³) CaCl₂•6H₂O 29 ~190 0.5-1.0 1710Commercial 53-65 190-250 ~0.2 800-930 Paraffin wax Myristic Acid 52.2182.6 n.a. 990

The PCM(s) can also be used for colder environment such as coolers,refrigerators, freezers, and the like. The PCM(s) for these uses can beselected based on the melting temperature of the components, which canbe chosen to match the desired regulated temperatures and/or ambienttemperatures as described in more detail here. The PCM(s) for cooler,refrigerator, and freezer application can comprise various inorganicmaterials, organic materials, and fatty acids in addition to othercomponents (e.g., commercial components that can serve as PCMs, etc.).In some embodiments, suitable PCM materials can include, but are notlimited to, LiClO₃·3H₂O, ZnCl₂·3H₂O, Eutectic water-salt solution:22.4-23.3 wt. % NaCl solution, Paraffin C14, Paraffin C15-C16,Polyglycol E400, Formic acid, propyl palmitate, isopropyl palmitate, RT5 (Paraffin; available from Rubitherm GmbH), RT 5 HC (Paraffin;available from Rubitherm GmbH), PureTemp 4 (Biobased product; availablefrom PureTemp LLC), ClimSel C7 (Salt hydrate; available from Climator),RT 8 (Paraffin; available from Rubitherm GmbH), RT 8 HC (Paraffin;available from Rubitherm GmbH), PureTemp 8 (Biobased product; availablefrom PureTemp LLC), RT9 (Paraffin; available from Rubitherm GmbH), RT 10(Paraffin; available from Rubitherm GmbH), RT 10 HC (Paraffin; availablefrom Rubitherm GmbH), PureTemp-21 (Biobased product; available fromPureTemp LLC), TH-21 (Salt hydrate; available from TEAP), SN21 (Saltsolution; available from Cristopia), STL-21 (Salt solution; availablefrom Mitsubishi Chemical), SN18 (Salt solution; available fromCristopia), TH-16 (Salt solution; TEAP), STL-16 (Salt solution;available from Mitsubishi Chemical), SN15 (Salt solution; available fromCristopia), PureTemp-15 (Biobased product; available from PureTemp LLC),and combinations thereof. Table 2 below provides some exemplary PCMsthat can be used for cooler, refrigerator, and freezer applications.

TABLE 2 Melting Latent Heat of PCM Temp. (C.) Fusion (kJ/kg) LiClO₃•3H₂O8.1 253 ZnCl₂•3H₂O 10 — Eutectic water-salt solution: 22.4-23.3 wt.−21.2 222-233 % NaCl solution Paraffin C₁₄ 4.5 165 Tetradecane 5.5 215Paraffin C₁₅-C₁₆ 8 153 Polyglycol E400 8 99.6 Formic acid 8 277 Propylpalmitate 10 186 Isopropyl palmitate 11  95-100 RT 5 (Paraffin;Rubitherm GmbH) 5 180 RT 5 HC (Paraffin; Rubitherm GmbH) 5 250 PureTemp4 (Biobased product; PureTemp 5 187 LLC) ClimSel C7 (Salt hydrate;Climator) 7 130 RT 8 (Paraffin; Rubitherm GmbH) 8 175 RT 8 HC (Paraffin;Rubitherm GmbH) 8 190 PureTemp 8 (Biobased product; PureTemp 8 178 LLC)RT9 (Paraffin; Rubitherm GmbH) 9 175 RT 10 (Paraffin; Rubitherm GmbH) 10160 RT 10 HC (Paraffin; Rubitherm GmbH) 10 200 PureTemp −21 (Biobasedproduct; −21 239 PureTemp LLC) TH-21 (Salt hydrate; TEAP) −21 222 SN21(Salt solution; Cristopia) −21 240 STL-21 (Salt solution; Mitsubishi −21240 Chemical) SN18 (Salt solution; Cristopia) −18 268 TH-16 (Saltsolution; TEAP) −16 289 STL-16 (Salt solution; Mitsubishi −16 —Chemical) SN15 (Salt (Salt solution; Cristopia) −15 311 PureTemp −15(Biobased product; −15 301 PureTemp LLC)

Other PCM compositions are possible based on the desired meltingtemperature of the PCM(s), which can depend on the specific temperatureof the location being regulated. For example, commercial processesmaintaining higher temperatures than buildings can utilize highermelting point PCM(s).

There can be advantages and disadvantages of using inorganic and organicmaterials as PCMs. Inorganic materials such as hydrated salts can havehigher volumetric thermal energy storage capacity, a higher volumetricphase change enthalpy, are non-flammable, and can have a lower costs.However, such inorganic materials can suffer from supercooling and phaseseparation issues while potentially being corrosive and lacking thermalstability. Organic materials may not have such problems to such anextent and tend to be more chemically and thermally stable. However,organic materials (e.g., paraffin wax, fatty acids, etc.) can beflammable, which can require additional components to control.

In some embodiments, mixtures of PCMs can be used with the porousmaterials. Mixtures of PCM(s) can have melting point ranges that mayallow the PCM(s) to melt over a broader temperature range than a purecomponent alone. The resulting mixture may then be useful over a broadrange of expected operating temperatures. The specific composition ofthe mixture can be selected for a desired melting temperature rangeselected for the location of the insulation. Further, the specificcomposition can be selected and blended to provide the desired meltingpoint range, for example spanning a small temperature range (e.g.,between about 1 to 10° C.), or a broader melting temperature range(e.g., between about 10 to 50° C.).

The PCM(s) can be combined with the insulation materials (e.g., a porousmaterial) in any suitable amount. In general, the use of the PCM(s) maystore heat, and a larger amount of PCM(s) in the porous material may becapable of storing larger amounts of heat. Increased amounts of thePCM(s) may be prone to leakage problems as well as being limited by thepore volume present in the porous material. In some embodiments, thePCM(s) may be used with the porous materials in a weight ratio ofbetween about 10:1 and 1:10, depending on the selection of the porousmaterial and the PCM(s).

In some embodiments, the PCM(s) can be present as macroencapsulatedPCM(s), microencapsulated PCM(s), nano-encapsulated PCM(s), and/orshape-stabilized PCM(s). In these embodiments, the PCM(s) can beencapsulated to retain the PCM within the layer. The use ofencapsulation or shape stabilization can allow the material to beincorporated into a porous or non-porous material in a defined formwhile preventing or reducing movement or leakage of the PCM(s) duringuse. Various materials can be used to encapsulate or stabilize thePCM(s) such as bio-based polymers, gelling agents, polymeric materials,or the like.

In some embodiments, the PCM(s) can be encapsulated in storagestructures such as pipes, panels, containers, or the like. In theseembodiments, the PCM(s) can be encapsulated in the storage containers,which can then be incorporated within a SIP to form an insulatingmaterial. The storage structures can serve to prevent leakage of thePCM(s) during use while effectively transferring heat into and out ofthe PCM(s).

The PCM(s) can be converted into the liquid phase during use, and theliquid PCM(s) may migrate within the material or the insulation whenthey are in the liquid phase. In addition, the PCM(s) can vaporize andhave vapor leakage of the PCM(s) from the porous materials. In someembodiments, a binder can be used with the PCM(s) to help to bind thePCM(s) in place within a porous material to thereby retain the PCM(s) inthe porous material even when in the liquid or vapor phase. The bindercan be combined with the PCM(s) to form a mixture and impregnated withinthe porous material along with the PCM(s). In some embodiments, thebinder can be used as a coating on the porous material having the PCM(s)disposed therein. A small amount of binder, such as epoxy, can allow thePCM to be bonded to the porous material. In some embodiments, the bindercan be used to form a seal on an outer layer of the porous material toretain the PCM(s) within the porous material even when in the liquidphase. The resulting coating or layer can absorb within a portion of thepores of the porous material and can partially mix with the PCM(s) tosome degree during the formation process. In some embodiments, one ormore binders can be mixed with the PCM(s) during the impregnationprocess of the porous material, and an additional coating layer can beapplied to an outer surface of the porous material when formed into alayer or panel to further retain the PCM(s) within the porous materialduring use.

Various binders can be used to increase the bonding between the PCM(s)and porous materials. In some embodiment, a resin or curable materialsuch as an epoxy can be used as the binder. The binder can then cureduring the preparation process to retain the PCM(s) in the porousmaterial. The binder may be an epoxy. Suitable epoxy compositions caninclude, but are not limited to, epoxy, phenoxy, alkyd, acrylic, vinyl,polyester, polyurethane resins, vinyl acetate/ethylene copolymeremulsions, high solids epoxies, acrylics, amine-cured epoxies,water-based latex, and/or combinations thereof. The binder can be a onepart or two-part formulation. In some embodiments, the binder can bepresent in the in an amount of between about 0.1 wt. % and about 10 wt.%, or between about 0.5 wt. % and about 8 wt. % with respect to theweight of the PCM(s).

The insulating material can also comprise a film coating in someembodiments. The film can be coated on an external surface of thecomposite insulation material with the PCM(s) disposed therein. The filmcan serve to retain the PCM(s) within the composite insulation materialduring use. This may be useful for PCM(s) that can sublimate, evaporate,or leak during use in either a solid or liquid phase. For example, someorganic PCM(s) may evaporate during use. The thin film can then serve asa barrier to such evaporation to prevent the migration of the PCM(s) outof the composite insulation material over time, which can degrade theinsulating properties of the composite insulation material.

As an example, the use of biodegradable porous materials with PCM(s)(e.g., organic or bio-based PCM(s)) impregnated within the porousstructures of the biomass fiber can suffer from leaking of molten PCM atelevated temperatures. The use of a thin film can help to eliminate orsignificantly reduce such leaking, thereby resulting in an effective PCMmodification on the biomass insulation such that the insulatingproperties of the biomass/PCM insulation is significantly improved.

When present, various types of films can be used. In some embodiments,the film can be a polymeric film (e.g., cellophane, polyurethane basedfiles, polyvinyl chloride based files, etc.), a biobased film such as asoy based thin film, a metallic film (e.g., a foil, facing, etc.), orthe like. When polymeric or biobased films are used, they can be heatsealed onto a composite insulation material to help to bind to and sealin the surface of the composite insulation material. In someembodiments, one or more layers of metal can be used to prevent leakagefrom the porous material, and the metallic films can have a thicknessfrom about 10 microns to about 8 mm. Thin films or foils can be used inaddition to or in place of polymeric based films to help to reduceleaking from the porous materials. Other films or panels, such as PVC,honeycomb, plastic, stainless steel, and aluminum panels, can also beused to encapsulate the PCMs.

To address one of the key risks of both flammable insulation materials(e.g., biodegradable materials, polymeric porous materials, etc.) andsome organic PCM(s) such as paraffin wax, which are flammable materials,an optional fire retardant treatment can be used with the compositeinsulation material. The fire retardant treatment can be combined withthe PCM(s) during formation of the materials, applied to the porousmaterials prior to impregnation of the PCM(s), and/or applied to asurface of the porous material after impregnation with the PCM(s).Various fire retardant treatments and composition, such as variousorganic acids (e.g., boric acid, carboxylic acid, etc.), organohalogenbased fire retardants (e.g., bromine based fire retardants),organophosphorous fire retardants, and the like, can be used for thecomposite material to meet the ASME fire retardant standard for thebuilding envelope material.

The PCM(s) can be disposed within the porous material in a number ofways. As shown in FIG. 1 , the PCM(s) can be disposed within the poresof the porous material such as bio-based porous materials. The pores canbe pre-existing in such materials as a result of their inherentstructures. In some embodiments, the pores can be formed in the porousmaterial along with impregnation of the PCM(s). For example, concrete,gypsum, or other materials can be formed in a liquid state and thePCM(s) can be combined with the materials in the liquid state to form anemulsion. In some embodiments, the PCM(s) can be encapsulated prior toor during this process to form encapsulated PCM(s) within the finalstructure, as described in more detail herein. Upon curing or drying,the porous material can encapsulate the PCM(s) within the material,thereby capturing the PCM(s) in place in the final materials.

In one non-limiting example of a resulting composite insulationmaterial, woody core from kenaf (Hibiscus cannobinus L) or hemp(Cannabis) can be used as biomass feedstocks. Compared to other biomassfibers, the woody core has a higher pore volume, and thus has much lowerdensity. Because of this reason, the kenaf or hemp woody core has beenused as bioabsorbent in some uses. For the same reason, the woody coreis a good candidate to be used as an insulation material for buildingconstructions. Some suitable PCMs are hydrophobic, such as paraffin wax.The kenaf or hemp woody cores are more hydrophobic compared to otherlignocellulosic fibers. Therefore, kenaf or hemp may be more compatibleto the hydrophobic paraffin wax treatment. The resulting compositematerial can be used to accomplish a high “effective” R-value compositefor efficient building energy savings.

In one non-limiting example, woody core from kenaf (Hibiscus cannobinusL) or hemp (Cannabis) is used as biomass feedstocks. Kenaf or hemp woodycore has been underutilized. Compared to other biomass fibers, the woodycore has much higher pore volume, and thus has much lower density.Because of this reason, the kenaf or hemp woody core has been used asbioabsorbent (www.kengro.com). For the same reason, the woody core is agood candidate to be used as an insulation material for buildingconstructions. Most of the PCMs are hydrophobic, such as paraffin wax.The kenaf or hemp woody cores are more hydrophobic compared to the bastfibers or other lignocellulosic fibers. Therefore, it is more compatibleto the hydrophobic paraffin wax treatment.

The PCM(s) can be provided within the insulating material in a number ofways. As noted above, the PCM(s) can be stored in the pores within aporous material, which can be formed into panels that can be combinedwith other insulating materials. In some embodiments, the PCM(s) can becaptured in a structure that can store the PCM(s) and allow theencapsulated PCM(s) to be incorporated into an insulating layer. Forexample, the PCM(s) can be provided as macroencapsulated PCM(s),microencapsulated PCM(s), nano-encapsulated PCM(s), and/orshape-stabilized PCM(s). In these embodiments, the PCM(s) can beincorporated into a material such as an insulation material or porousmaterial that can be formed into a panel or other insulating structure.

For example, insulating materials such as foam board can be formed withthe PCM(s) to improve the insulating properties. In some embodiments,the insulating material can be a polyurethane foam that can incorporateencapsulated or unencapsulated PCM(s) to form a polyurethane-PCMcomposite material. The PCM(s) can be incorporated during themanufacturing process of the polyurethane board so that the PCM(s) areretained within the cured foam itself. The resulting compositeinsulation materials can have improved temperature buffering to helpretain temperatures and improve the insulating properties of thematerials.

FIG. 2 illustrates a perspective view of another embodiment 200 ofencapsulated PCM(s) 206 within a panel based construction 202. As shown,the PCM(s) 206 can be disposed within containers such as pores, holes,or the like within the panel 202. As shown in FIG. 2 , the container canbe in the form of a honeycomb structure 204 that can be used to containthe PCM(s) 206. The PCM(s) can comprise any of those described herein.The resulting containers with the PCM(s) therein can form the panel 202with two covers 208 used to seal the panel 202. The resulting panel 202can then be used as an insulating material or layer within a building orinsulating structure.

Using a container as described with respect to FIG. 2 can provide a highstorage capacity of the PCM(s) 206 within the panel 202. In order toaccount for the additional work used to prepare such panels, they can bepre-prepared in a desired size and shape for use in a buildingstructure. In some embodiments, the encapsulated PCM(s) can be used withother materials such as the drywall or concrete. This use of theencapsulated PCM(s) in such materials may not affect the strength of thematerials while still providing a less expensive and workable solutionon site. Such materials can lead to an improved thermal inertia as wellas lower inner temperatures for the panels and structure.

In some embodiments, the insulating materials can comprisemacro-encapsulated PCM(s) such as storing the PCM(s) in containers orstorage structures such as pipes. As shown in FIG. 3A, an encapsulationsystem 300 can comprise the PCM(s) 304 being encapsulated in one or morepipes 302. In this embodiment, the PCM(s) can be stored in a storagestructure comprising one or more pipes 302. When pipes are used, thepipes 302 can be formed from a thermally conductive material such as ametal (e.g., copper, steel, etc.). Once filled, the storage structurecan be sealed to encapsulate the PCM(s) 304. The resulting storagestructures can then be embedded within SIPs to form a PCM basedinsulating material. In some embodiments as shown in FIG. 3B, the PCM(s)304 can be stored in a container 310 that can comprise a flat geometryto match a layer in an insulation system. For example, a panel likecontainer 310 that can be a tank or vessel 306 can be formed having asheet-like configuration that can be filled with the PCM(s) 304. Thecontainer 310 can then be used as a layer in an insulation system.

The resulting composite insulation material can be used to form a panelor layer within an insulation system (e.g., comprising one or morelayers of the composite insulation material along with one or moreoptional layers of insulation materials). For example, the compositeinsulation material comprising the PCM(s) can be cast, pressed, orformed into a panel that can be used alone or with other insulatingmaterials to form an insulation system. FIG. 4 shows a construction ofwall integrated with a composite insulation material as described above.As shown, the composite insulation material 402 can be disposed within awall structure 403 that can comprise additional insulating layers. Thewall structure 403 can have a first side 404 that can be exposed to avarying temperature source 408, such as the sun. A second side 406 canbe adjacent or facing an ambient environment that is being regulatedsuch as the interior of a building. The first side 404 can be consideredthe high temperature side, and the second side 406 can be considered thelow temperature side. As illustrated, the temperature profile 410 can behigher on the first side 404 and lower on the second side 406. As alsoshown, the temperature profile may be non-linear within the wallstructure 403 as a result of the presence of the composite insulationmaterial 402 comprising the PCM(s) impregnated therein. While shown as apotential wall structure 403, other types of building structures arealso contemplated such as walls, floors, ceilings, shutters, windows,and the like to allow for efficient building temperature control, all ofwhich are considered building structures.

When formed as panels, the composite insulation materials can haveinterlocking structures on the edges. The interlocking structures can bedesigned to fit together so that when two adjacent wall panels areassembled to form the wall construction, the interlocking strictures ofone wall panel can interlock with reciprocal interlocking structures ofthe adjacent wall panel. Interlocking structures may be shaped as anarrow and receptacle, a rib and groove, interlocking channels, snap fitarrangements, or the like. When constructed, the panels may beseamlessly connected such that interlocking means are designed so that aflat external surface is provided, particularly on the interior side ofthe wall construction. It is advantageous that the connection pointsbetween adjacent wall panels be visible from outside the wall only as athin seam, the external surfaces of the wall panels together forming anuninterrupted flat surface, except for the seam.

The panels formed from the composite insulation materials may havevarious heights, widths, and thicknesses. Exemplary heights and widthsmay range from 3′-12′ or may range from 1-4 meters. For wallconstruction, the panels can be constructed according to standardbuilding sizes, for example matching drywall shapes and sizes or fittingbetween studs forming the walls. Thus, heights from about 4 feet (1.2meter) or higher, for example from 7 feet (2.1 meter) or 8 feet (2.4meter) up to about 15 feet (4.6 meter) can be suitable. A thickness ofthe panels may range from 0.25″ to 24″, depending on the whether or notany other layers are used in the insulation system and the availablespace for the insulation system.

The panels can also contain a number of additional features that can beformed as part of the panel formation process or formed after a panel iscreated. For example, FIG. 5 illustrates the panels containing optionalstructures, such as a conduit 502 for services such as data, phone,cable, electrical, plumbing, heating, ventilation, air conditioning andthe like. In some embodiments, the panels may have reinforcing supportssuch as rebars, long fibers, and the like. Note that supports can haveother uses besides providing structural support for the panel. Forexample, supports may also be piping/conduit for plumbing, drains, airvents, electrical, cable, data and phone lines, heating, ventilation airconditioning components, and the like.

In some embodiments, the panels may have openings 504 for any desiredwindows, doors, or the like, and the openings can be made by cuttingappropriately sized and positioned holes through the assembled panelsystem before adding the load-bearing material. If desired, theseopenings can be made on-site, or can be pre-cut into the wall panels atthe point of their manufacture. The periphery of the opening can then beframed out prior to forming the load bearing material. Pre-manufacturedwindow or door seats can be used for this purpose. Advantageously, theframing can adhere to the load bearing material. After the wallconstruction is completed, the door or window casing can be attached tothe framing and trimmed out as desired.

In some embodiments, the panels may have other structural or functionalcomponents to the form an assemblage, such as, for example, a moistureor vapor barrier sheet or film. This sheet can be the same as the filmapplied for purposes of preventing leakage of the PCM(s) from thecomposite insulation material, or it can be a different or additionallayer. For convenience, the moisture or vapor barrier film may beattached to the inside surface of either or both of the interior andexterior wall panels or to either or both sides of the insulating foampanels prior to assembling the form assemblage. Other structural orfunctional components include, for example, protruding bolts or otherfasteners for attachment of a roof, eaves, ceiling, trusses, and thelike; cut-outs for joists, rafters and the like, protruding reinforcingrods or bars, and the like.

In some embodiment, the panels may have one or more facers employed in apanel formed from a composite insulation material, as shown in FIG. 6 .Metal facers 604 employed in the composite panels 602 may be one or moreof galvanized steel, stainless steel, copper, aluminum, metal foils ofaluminum or steel, strip steel, coiled steel, or other appropriate metalmaterial. The metal is preferably coiled steel. The metal surface may bezinc-coated, aluminum/zinc coated, zinc/iron coated, hot-dip galvanizedto provide corrosion resistance or the metal facer may be exposed toother treatment steps such as chemical cleaning, plating, and thermaltreatment. A typical thicknesses of a metal facer can be less than 8 mm,and it may be as thin as 10 microns (foil). Preferred steel facers havea thickness of from 0.8 to 0.3 mm. Other facer materials such asreinforced fiber board, oriented strandboard, or reinforced paper mayalso be used.

In some embodiments, the panels may have an intumescent coating employedin providing fire resistance to the composite insulating panel. Thecomponents of an intumescent coating can generally comprise a binder(such as epoxy or latex), a catalyst (such as an acid donor likeammonium polyphosphate), a blowing agent or spumific (such as melamine),and a polyhydridic carbon donor that forms a char on application ofheat. These intumescent coatings are of the type that provide aninsulating char barrier having a thickness many times their originalthickness at char temperatures of approximately 200-300° C. Often, thethickness can reach a height of 1 mm and greater when exposed to atemperature of 500° C. for 5 minutes. This thick carbon char offersthermal protection to the underlying substrate in that it limits heattransfer through the panel thus greatly reducing thermal decomposition,charring, melting, and formation of flammable or pyrophoric gases whichcan be generated from pyrolysis or decomposition of the core material ofthe insulating panel.

In some embodiments, the composite materials can comprise a single layerof the insulating material with one or more layers of additionalmaterials (e.g., traditional insulation, etc.). In some embodiments, aplurality of layers of composite insulation materials comprising PCM(s)can be present, where each layer can be the same or different withregard to the type of composite insulation material (e.g., PCM(s) in aporous material, encapsulated PCM(s) in a material, PCM(s) in containerswithin the insulating layer, etc.), the type of PCM(s), and/or thedimensions of the layers. The use of a plurality of layers can allow forPCM(s) with different melting temperature or melting temperature rangesto be used from a hot side to a cold side, thereby providing a greaterinsulating capacity across the insulating system.

FIG. 7A-7E shows a number of embodiments of different arrangement oflayers within an overall insulating system. Within FIGS. 7A-7E,reference will be made to a cold side being regulated on the left and ahot side on the right. Starting with FIG. 7A, a PCM or a PCM formulation(e.g., a mixture of two or more selected PCMs to achieve the a desiredmelting temperature range and latent heat of fusion) can be encapsulatedwithin a container 702 with designed dimensions to form a compositeinsulation material, and then placed on the inner wall of an insulationmaterial 704 to form an overall insulation system 700. The insulationmaterial 704 can comprise any type of insulation such as a polyurethanefoam, fiberglass, Styrofoam, cellulosic insulation, or the like. Thisdemonstrates the use of a single layer of a container with PCM(s) alongwith an insulation material to form an insulating layer or system.

The container can form an enclosure into which the PCM(s) can be placed.The container can include any of the designs noted above including theuse of PCM(s) in a porous material, encapsulated PCM(s) contained withinthe container, and/or a container filled with the PCM(s) without anyadditional components included. The container 702 can be made from aplastic, metal, or other material suitable for containing the PCM(s)while limiting or reducing leaking of the PCM(s) from the container 702.In some embodiments, the container can have an outside thickness ofbetween about 0.25 inches and about 10 inches, or between about 0.5inches and about 6 inches (depending on the insulation requirements andthe thickness of the insulation wall). The length and width of thecontainer can be selected to match the desired insulation layer or wallsize. The selected PCM or PCM formulation can comprise any of thosePCM(s) described herein. While shown as a rectilinear container, othershapes including the use of a plurality of pipes can also be used tocontain the PCM(s) and form a layer in the insulation layer. Thecontainer with the PCM(s) can be bonded to the wall of the insulationmaterial (e.g., using an adhesive, etc.) and/or placed in a bracket orother attachment device at the inner face of the insulation layer toform an insulation system.

As shown in FIG. 7A, the thickness of each of the container 702 and theinsulation material 704 can be the same or different. For example, theinsulation material can have an outside thickness of between about 0.1inches and about 10 inches, or between about 0.25 inches and about 6inches (depending on the insulation requirements and the thickness ofthe insulation wall). As also shown, the container can be arranged on aninside surface closest to the environment being regulated, and theinsulation material 704 can be positioned closest to a hot environment.In some embodiments, the ordering of the layers can be reversed, and insuch embodiments, the selection of the PCM(s) may be different toaccount for the expected temperatures on the hot side of the insulationlayer.

FIG. 7B illustrates a system similar to that shown in FIG. 7A, andsimilar elements can be numbered the same. As shown in FIG. 7B, acontainer 702 with PCM(s) encapsulated therein can be disposed betweentwo layers of insulation material 704. The container can be similar orthe same as the container 702 as described with respect to FIG. 7A.Similarly, the insulation materials 704 can be the same or similar tothe insulation materials as described with respect to FIG. 7A. In thisembodiment, the container encapsulating the PCM(s) can be placed at thecore of the insulation system to form a structure similar to a sandwichlayup. In some embodiments, the container can be bonded (e.g., using anadhesive, etc.) to one or both of the insulation material 704 layers. Inother embodiments, the three layers can be placed adjacent to each otherand retained in position based on the installation within the insulationlayer or system.

As shown in FIG. 7B, the container can have a thickness similar to thatof the container 702 described with respect to FIG. 7A, and theindividual thickness of the insulation materials 704 can be within therange described with respect to FIG. 7A. The individual thickness of thetwo insulation material layers can be the same or different. Forexample, the insulation material 704 layer closest to the environmentbeing regulated can be the same, thicker than, or thinner than theinsulation material 704 layer closest to the hot side, depending on thetemperature requirement of the controlled environment.

FIG. 7C illustrates an embodiment in which a layer of a compositeinsulation material 706 formed form a porous material containing thePCM(s) can be contained between two layers of insulation material 704.In this embodiment, the composite insulation material 706 layers can bethe same or similar to those described with respect to FIG. 7B, and thesimilar elements and dimensions will not be repeated for the sake ofbrevity.

As shown in FIG. 7C, the core material can comprise a porous materialhaving the PCM(s) contained therein and formed into a panel type layerto form the composite insulation material 706. The composite insulationmaterial 706 can include any of the porous materials as described hereinwith any of the PCM(s) described herein impregnated in the porousmaterial. In some embodiments, the porous material forming theinsulating layer 706 can be the same or similar to the insulationmaterials forming the insulation material 704 layers. This can allow thecomposition of the insulation material to be consistent across the crosssection with the exception that the PCM(s) can be impregnated into asection of the insulation material between at least two outer sectionsthat do not have the PCM(s) impregnated therein. The compositeinsulation material 706 can form a layer within the overall insulationsystem that can have a thickness between about 0.1 inches and about 10inches, or between about 0.25 inches and about 6 inches, depending onthe insulation wall size and insulation design.

In some embodiments, the composite insulation material 706 can have afilm or foil covering the layer to help prevent leakage from thecomposite insulation material 706. The film or foil can include any ofthose described herein, and the layer can be adhered and/or heat sealedonto the composite insulation material 706. When a film is used, thecoating of the film onto the composite insulation layer can beintegrated into the fabrication of the composite insulation material706. The composite insulation material 706 can then be bonded (e.g.,using an adhesive or coupling mechanism, etc.) to the outer insulationmaterial 704 layers and/or disposed in the insulation layer uponinstallation.

FIG. 7D illustrates an insulation layer having two layers containing thePCM(s) with one layer of insulation material 704 not having the PCM(s).The two layers can comprise a first layer 708 and a second layer 710.The first layer can comprise a container having encapsulated PCM(s)disposed therein. The second layer 710 can comprise a container havingencapsulated PCM(s) disposed therein. While shown as includingcontainers, the first layer 708 and/or the second layer 710 can alsocomprise a composite insulation material formed from a porous materialhaving one or more PCM(s) impregnated therein and formed into aninsulating layer.

The first layer 708 and the second layer 710 can comprise any of thecomposite materials as described herein, including any of the PCM(s) asdescribed herein. The selection of the PCM(s) in each of the first layer708 and the second layer 710 can vary. In some embodiments, a meltingpoint or melting point range of the first layer 708 can be lower thanthe melting point or melting point range of the second layer 710. Insome embodiments, the melting point of the second layer 710 can bebetween about 5 to about 20 degrees ° C. higher than the melting pointof the first layer 708.

While shown as a first layer 708 and a second layer 710 in FIG. 7D,additional layers can be present. In some embodiments, three, four,five, or more composite insulation layers can be present. When multiplelayers are present, the melting point or melting point ranges cangenerally be the lowest in the layers closest to the environment beingregulated and increase towards the hot side of the insulation layer. Forexample, each adjacent layer in multi-layer assembly may have a meltingpoint or melting point range increasing by about 1 to about 20 degrees °C. as the layers approach the hot side of the insulation layer. Someamount of overlap in the melting point or melting point ranges may occuras the number of layers increases.

The thickness of the first layer 708 and the second layer 710 can varybetween each layer, and the layers may generally have a thicknessbetween about 0.1 inches and about 5 inches, or between about 0.5 inchesand about 3 inches. As the number of layers increases, each individuallayer may be thinner to allow the overall thickness of the insulationassembly to have a desired thickness for the insulation space available.Each layer can be bonded to the adjacent layers or the layers can eachbe placed in a bracket or otherwise affixed into position within theinsulation assembly.

FIG. 7E illustrates an insulation system similar to that described withrespect to FIG. 7D, and the similar components can be the same orsimilar to those described in FIG. 7E. As shown in FIG. 7E, two or morelayers of composite insulation material can be present in the insulationsystem. At least a first layer 708 can be on a surface closest to theenvironment being regulated and at least a second layer 712 can be on asurface closest to the hot side of the insulation system. An insulationmaterial 704 can be disposed between the first layer 708 and the secondlayer 712. Additional layers of composite insulation material can alsobe present in the insulation system between the first layer 708 and thesecond layer 712. For example, a total of 3, 4, 5, or more layers arepossible in the insulation system as shown in FIG. 7E.

The first layer 708 can be the same or similar to the first layer 708 asdescribed with respect to FIG. 7D. The second layer 712 can have thesame structure and thicknesses as described with respect to the secondlayer 710 in FIG. 7D. The selection of the PCM(s) in the second layer712 can provide PCM(s) having a melting point or melting point range ator below the expected ambient operating temperatures on the hot side,which is above the melting point or melting point range of the firstlayer 708. When multiple layers of composite insulation material arepresent, the melting point or melting point ranges can generallyincrease from the first layer 708 to the second layer 712. Each layer inthe insulation assembly can be bonded to the adjacent layers or thelayers can each be placed in a bracket or otherwise affixed intoposition within the insulation assembly.

In some embodiments, the insulated materials can be used for insulatingcooled or refrigerated compartments. For example, any of the embodimentsdescribed with respect to FIGS. 7A-7E can be used for one or moreinsulation systems (e.g., walls, enclosures, etc.) within a cooler,refrigerator, or freezer. The selection of the PCM(s) can be made on thebasis of the temperature being maintained within the cooler,refrigerator, or freezer and/or a location of the composite insulatingmaterial relative to the interior of the cooler, refrigerator, orfreezer. For example, for freezer insulation, the PCMs as well as PCMformulations with a melting point of about −40 to about 0° C. can beused, and for cooler insulation, the PCMs as well as PCM formulationswith a melting point of about −5 to about 10° C. can be used.

For example, for a −23° C. freezer insulation using a design as shown inFIG. 7A, a PCM with a melting temperature range of about −23 to about−15° C. could be used. Referring to Table 2, suitable PCM(s) can includea eutectic water-salt solution (22.4-23.3 wt. % NaCl solution) with amelting point of −21.2° C., PureTemp-21 (Biobased product; availablefrom PureTemp LLC) with a melting temperature of −21° C., or another PCMwith the similar melting temperature range. Similarly, for a 2° C.cooler using the design as shown in FIG. 7A, a PCM with a meltingtemperature range of 2-10° C. could be used. The PCM selection caninclude LiClO₃.3H₂O (melting temperature of 8.1° C.), Paraffin C14(melting temperature of 4.5° C.), Formic acid (melting temperature of 8°C.) or any commercial PCM, such as RT 5 (Paraffin; available fromRubitherm GmbH) (melting temperature of 5° C.). Similar considerationscan apply to the designs shown in FIGS. 7B-7D. In the design shown inFIG. 7D, for a freezer, the first layer 708 can have the melting pointof about −21° C., while the second layer 710 can have a melting pointthat is the range of about −15 to about −2° C.

The insulating material can be formed in a number of ways. In general,the PCM(s) can be melted to form a liquid PCM, which can then becombined with the porous material to allow the PCM(s) to impregnate thepores of the porous materials. When the PCM(s) impregnate the porousmaterial, the insulated material can be formed. A number ofincorporation methods can be used to incorporate PCMs within the porousmaterial including direct mixing of the liquid PCM(s) with the porousmaterial, and/or immersion of the porous materials in a bath of moltenPCM, macroencapsulated PCM(s), microencapsulated PCM(s),nano-encapsulated PCM(s), and/or shape-stabilized PCM(s).

For the impregnation method, the porous material can be obtained andprepared for impregnation. In some embodiments, the porous material canbe optionally prepared by being ground or sized to have a desired sizeand/or shape. For example, the porous material such as a bio-basedporous material can be ground to a desired size. The size of the porousmaterial may be selected to allow for the formation of the insulatingmaterial into a desired shape when impregnated with the PCM(s).

Further, various treatments can be used to prepare the porous material.For bio-based materials, a chemical treatment such as treatment with aweak base (e.g., 5% NaOH) can be used to remove some of the lignin andprovide a greater pore volume of the biomass material. Other chemicaltreatments may also be used to modify the surface properties of thepores to allow the PCM(s) and any optional binders to impregnate andbond to the porous materials.

Once the porous materials are prepared, the PCM(s) can be selected andblended if more than one PCM is being used. When a binder is present,the binder can be combined with the PCM(s) to form a mixture having anyof the binders and weight percentages as described herein. When a flameretardant is used, it can be combined with the mixture or applied afterthe porous material is impregnated.

The PCM(s) and optional binder can then be contacted with the porousmaterial. In order to retain the PCM(s) in the liquid phase, a reactorcan be used that is heated during the impregnation process. Thetemperature can be maintained above the melting point or range of thePCM(s). For example, the temperature within the reactor can bemaintained at least 2-5° C. above the melting point of the PCM(s). Insome embodiments, the temperature of the reactor can be maintainedbetween about 30° C. to about 80° C. during the impregnation process. Insome embodiments, pressure can also be applied to drive the PCM(s) intothe pores of the porous material. The pressure can be at least about 50psia, at least about 75 psia, or at least about 100 psia. Theimpregnation process can continue for about 10 minutes to about 10hours, or for about 10 minutes to one hour. When a binder is present,the reaction time may be based on the reaction time of the binder toallow the binder to fully cure prior to releasing the pressure orlowering the temperature.

In some embodiments, the desired amount of the PCM(s) can be combined inthe liquid phase with the porous material. This can be referred to asthe direct mixing method. The reaction may continue along with mixing ofthe porous material until the PCM(s) are fully absorbed and impregnatedinto the porous material. Other processes can comprise using an excessof the PCM material and immersing the porous material in the moltenPCM(s). After a desired time, excess PCM(s) can be removed at elevatedtemperature from the reactor to leave the porous material having thedesired amount of PCM(s) impregnated therein. The reaction conditions(e.g., temperature, time, pressure, etc.) can be controlled to allow fora desired amount of the PCM(s) to be absorbed and impregnate into theporous material in the immersion method.

Once reacted, the resulting insulating material can be formed into adesired structure. In some embodiments, the insulating material can beformed in a planar layer by providing the impregnated porous material toa mold. A press can be used to form the layer within the mold prior tothe removal of the insulating layer. When used to form an insulatingstructure, one or more additional insulating materials can be layeredwith the insulating material and pressed to form the final structure.

When a film is used with the insulating materials, the film can be usedon one or more surfaces of the resulting insulating layer after it isremoved from the mold. For example, a film can be applied to both sidesof the insulating layer, and in some embodiments the edges can besealed. Heat an optionally be applied to allow the film to melt into theinsulating material to enclose the insulating material and preventleakage of the PCM(s) during use. In some embodiments, the optionalflame retardant can be applied after the film is applied to theinsulating layer. Flame tests can be conducted in accordance with theprocedure described in ASTM D6413 (e.g., the latest version as of thefiling of this application) on the insulated material to evaluate thefire resistant properties.

The process as described above is illustrated in FIGS. 8A-8C for theimpregnation of a porous material comprising processed wood with a PCMcomprising paraffin wax. As shown in FIG. 8A, a woody core can beprepared by being ground to a desired size, and the PCM can be providedin a solid phase. The process described herein can then be used to meltthe paraffin wax and impregnate the woody core with the melted paraffin.The resulting material is shown in FIG. 8B. The resulting material canthen be used in a mold to form a final layer as shown in FIG. 8C. Thisfabrication process is possible for large-scale manufacture. Multiplelarge-scale 2 feet (Width)×4 feet (Length)×3 inch (thickness) SIP panelscan be fabricated and delivered based on the above impregnation process.

During the impregnation process, the properties of the porous materialcan be matched to those of the PCM(s) to obtain better infiltration andimpregnation. For example, the hydrophobic/hydrophilic properties of thePCM(s) can be matched to those of the porous material to obtain betterimpregnation of the PCM(s) by matching the wetting properties. If theproperties are not matched, an optional pre-processing step can becarried out on the porous material to modify the hydrophobic/hydrophilicproperties to better match the properties of the PCM(s). By improvingthe impregnation, the thermal properties of the resulting compositeinsulation materials can be improved.

In addition to the direct mixing and immersion processes, otherimpregnation methods can also be used. Another incorporation method caninclude embedding macro-encapsulated, microencapsulated ornano-encapsulated PCMs in porous materials such as building materials.In these embodiments, the PCM(s) can be provided in an encapsulated formand combined with the materials used to for the porous materials. Forexample, encapsulated or shape stabilized PCM(s) can be combined withconcrete, gypsum, polymers, foams (e.g., polyurethane foams, etc.), orother materials that can be processed to form panels or other insulatingor structural materials. The encapsulated PCM(s) can then function tostore heat within the encapsulations within the resulting insulatingmaterials. The encapsulation can serve to prevent leakage of the PCM(s)during use. Such methods may increase the insulating values or standardbuilding materials.

In some embodiments, the encapsulation may comprise macroencapsulationsuch as storing the PCM(s) in storage structures such as containers orpipes. In this embodiment, the PCM(s) can be melted and used to fill astorage structure. Storage structures within the containers or pipes canbe present. For example, honeycomb shaped pores or other porousstructures can be within the containers to help to retain the PCM(s) inposition when in a liquid phase. When pipes are used, the pipes can beformed from a thermally conductive material such as a metal (e.g.,copper, steel, etc.). Once filled, the storage structure can be sealedto encapsulate the PCM(s). The resulting storage structures can then beembedded within SIPs to form a PCM based insulating system according toany of the embodiments disclosed herein (e.g., as a stand-alone layer,as a layer in an insulation system, etc.). This formation method mayproviding for a sealed PCM that can have a relatively large weightloading of the PCM material. The storage structures can be aligned witha desired density within the SIP to provide a layer having theencapsulated PCM(s) within a wall or other insulating structure.

Once formed, the composite insulation material or materials can be usedto insulate a regulated environment from an external environment. Duringthe insulation process, a hot side of an insulation layer, which cancomprise a composite insulation material, can transfer heat through theinsulation layer to a cold side. During the insulation process, one ormore solid phase PCMs within the composite insulation material can bemelted in response to the transfer of heat through the insulation layer.The phase change from a solid phase to a liquid phase can occur at aspecific melting point temperature and/or over a melting point range.The effect of the phase change can be to absorb or store energy at atemperature defined by the melting point or melting point range. Duringthe phase change process, the result can include a reduced transmissionof heat through the insulation layer as it is absorbed by the phasechange of the PCM(s). The PCM(s) in the insulation layer can include anyof those described herein and at least one layer in the insulation layercan comprise any of the composite insulation materials as describedherein.

The heat passing through the insulation layer may eventually melt all ofthe PCM(s) in the insulation layer, at which time the heat can pass intothe regulated environment to warm the environment. The environment canthen be regulated by a cooling system to cool the environment. Duringthis process, the reverse process can occur as more heat is withdrawnfrom the environment than can transfer through the insulation layer. Thetemperature of the PCM(s) may then be reduced below the melting point ormelting point range of the PCM(s), and any liquid phase PCM(s) cansolidify at the melting point or melting point range. The process canoccur during the cooling cycle, which can allow the cooling system(e.g., a compressor driven air conditioner, refrigerator, or freezersystem) to run until the heat has been withdrawn from the PCM(s) withinthe insulation layer. This may allow the cooling system to operate moreefficiently as the cycle time can be extended to provide fewerstart/stop cycles.

It can be noted that the same process can occur with a heatedenvironment where the cold side of the insulation layer can beconsidered the exterior of the regulated environment. In this process,the PCM(s) can start in the liquid phase and gradually solidify as theheat transfers from the regulated environment to the cooler externalenvironment. Once fully solidified, a heat source can be used to reheatthe regulated environment and melt the PCM(s) at a nearly constanttemperature. This can allow the heat to be used less frequently based onthe solidification process releasing heat into the environment.

The use of the composite insulation materials in an insulation systemcan help to provide additional insulation value as well as makingenvironmental control systems more efficient. An example of suchefficiency can be provided by an improvement in the running time of acooling or refrigeration system within a space being cooled. It isexpected that the use of the PCM(s) in the composite insulation materialcan significantly improve the cooling system efficiency. FIG. 9 is agraph illustrating the time ratio between discharging and charging foran insulation comprising a 1-inch thick PCM layer versus a 6-inch thickPU foam (the base line). As used in this example, charging refers to thecontinuous running time of a compressor in the cooling system, whiledischarging refers to the time when the compressor is not running. Forthe base line case, the outer environmental temperature is the roomtemperature of 25° C. For PCM layer, the outer temperature is shown asincreasing in temperature difference along the graph between 1° C. to19.5° C. higher than the cooler/freezer compartment temperature. FIG. 9displays heat transfer simulation results of the discharging andcharging time comparisons when only a single layer of the compositeinsulation material comprising the PCM having a 1-inch thickness is usedas the insulation for the freezer. As shown in FIG. 9 , as thetemperature difference between the inner and outer side of the compositeinsulation layer is lowered, the energy savings can be increased basedon the time ratio between discharging and charging (wherein the timeratio refers to the discharging time/charging time). A larger ratioindicates the electricity consumption from the compressor is lowered andmore efficient. With around a 19° C. temperature difference, the timeratio is approximately four times higher than that of the base line,leading to a significantly increased energy savings for thecooler/freezer.

A similar scenario further illustrates the improvements of the use ofthe composite insulation material. As shown in FIG. 10 , a graphillustrating a comparison of the time ratio between discharging andcharging for various thicknesses of PU foam outside of a 1-inch thicklayer of a composite insulation material comprising a PCM. As shown, asthe thickness of the layer of the PU foam increases, the energy savingscan also increase, and as compared to the baseline of using PU foamalone, the energy efficiency can demonstrate significant improvements.With the usage of the composite insulation material, the thickness ofthe PU layer needed can also be decreased. For the case of a 1-inchthick PU foam outside of the 1-inch composite insulation material layer,the time ratio between discharging and charging (e.g., as indicative ofthe energy savings) is approximately four times higher than that of thebase line.

In some embodiments, it is expected that a life cycle analysis of theuse of the composite insulation materials comprising PCM(s) as describedherein can have an improved energy efficiency in the range of 5% to 300%(using the criteria described in Example 7) as compared to syntheticfiber insulation materials without the PCM(s). In some embodiments, theimproved energy efficiency may include a range from 5%-8%, from 5%-20%,from 5%-50%, from 20%-75%, from 50%-150%, from at least 5%, from atleast 10%, and from at least 20% energy efficiency. Compared to thesynthetic fiber insulation materials, the composite insulation materialscomprising the PCM(s) can present advantages for the environmental andcost benefits of the insulation.

EXAMPLES

The embodiments having been generally described, the following examplesare given as particular embodiments of the disclosure and to demonstratethe practice and advantages thereof. It is understood that the examplesare given by way of illustration and are not intended to limit thespecification or the claims in any manner.

Example 1 Building Energy Modeling and Cost Analysis

The effect of PCM(s) on building energy savings can be numericallypredicted using modeling methods for PCM-integrated buildingsimulations, and specifically the heat capacity method, which is able tobe integrated into prevalent building simulation programs, such asEnergyPlus, TRNSYS, and the like.

The EnergyPlus program (available from U.S. Department of Energy (DOE))can be used for PCM-impregnated cell, cabin, or house prediction. TheEnergyPlus program combined with the model of the composite insulationmaterials may be verified and validated through analytical method andexperimental measurements. The models and methods can show that the useof PCM-based wallboards (e.g., the composite insulation materials asdescribed herein) can improve the thermal inertia of buildings andreduce indoor temperature fluctuations up to 4° C. in a cabin on atypical summer day. These models and methods can also show thatinstallation of the PCM based materials has a positive effect on thermalcomfort and reduces the annual overheated hours from about 400 to 200 ina two-story apartment house.

In another model, a prototype house and its HVAC system may be modeledand simulated in the TRNSYS environment. TRNSYS is a transient systemsimulation tool for a variety of applications, including buildingsimulation, energy system research, etc. The simulation reveals thatwith the proper selection of PCM based materials based on the meltingpoint, it could achieve a substantial reduction in the total coolingdemand up to 85% compared to a prototype house without the embedded PCMbased materials. Additional TRNSYS type models simulate the thermalbehavior of a cell with PCM-integrated wall structure.

Besides the building energy simulation programs, there are other methodsto simulate the heat transfer performance of building wall structures,leading to the evaluation of the potential building energy savings. Oneexample contemplated for use herein is the finite volume method, whichsolves the one-dimensional, transient heat conduction equation through amulti-layered PCM enhanced wall using the typical meteorological year(TMY3) data for the exterior boundary condition. The numericalsimulation results demonstrated that the PCM composite wallboard couldreduce the energy consumption and shift the peak electricity load insummer. Cost analysis for PCM-enhanced building envelopes in southernU.S. climates can estimate a payback period of ˜5-10 years forPCM-enhanced gypsum board applications in the buildings in Phoenix,Arizona based on the PCM prices ≤$3.50/lb.

Example 2 PCM Incorporated in Biodegradable Materials

The use of paraffin wax (PCM) infiltrated into pine wood and woody corefrom kenaf through an immersion process was studied. The thermalproperties (i.e., thermal conductivity, specific heat, latent heat offusion, etc.) of the PCM treated biomass were characterized. It revealedthat the woody core had a better infiltration rate with paraffin waxthan wood due to the same hydrophobic property of natural plant materialcellulose and wax. Hence, the latent heat capacity of woody core-PCMcomposite during the phase change process was approximately two timeshigher than that of wood-PCM composite based on the DifferentialScanning Calorimetry (DSC) measurements.

Example 3

Referring to FIGS. 11A-11B, preliminary building energy simulations wereperformed on a lab building using the EnergyPlus simulation tool. Theabove PCM-enhanced composites from Example 2 were applied in the roofand one side of the wall structure of the lab in the simulation model.Through the simulations, the PCM was able to save annual heating load byup to 16% and annual cooling power by up to 11% when applying the woodycore-PCM composite to the lab structure, as displayed in FIGS. 11A-11B.The energy savings were less when using the wood-PCM composite due tothe lower infiltration rate in woods. Through the experimental andnumerical studies, it preliminarily demonstrated the wetting theory forthe PCM and porous matrix such that the two materials should have thesame or similar hydrophobic/hydrophilic properties to achieve betterinfiltration rate and higher thermal heat capacity.

Referring to FIG. 12 , the wall internal surface temperature is shownwith respect to various R-values of the insulation with/without PCMembedded. Moreover, heat transfer simulations were conducted for aone-inch thick SIP in the summer weather condition through thecommercial software COMSOL Multiphysics (available from COMSOLMultiphysics®). The outside temperature was 37° C. (98.6° F.: typicalsummer temperature in southern U.S.). From the simulation results shownin FIG. 12 , it is noted that the insulation R-value of 3 withinfiltrated PCM could achieve the same indoor condition (based on thewall internal surface temperature) as that of a material having anR-value of 10 without the PCM. It proves that the PCM has the potentialto improve the “effective” R-value above 10 without significantlyincreasing the instinctive (“actual”) R-value (e.g., by maintainingaround R-3/inch thickness). The effect of infiltrated PCM on the porousbiodegradable material instinctive R-value is reduced when the pore sizeis small.

Example 4 Measurement Equipment and Manufacturing Capabilities

A self-contained 1,200-ft² building facility with sub-meteringcapabilities for validation and simulation of whole building systemperformance is shown. Operating components include solar panels, solarwater heating, wind turbine, geothermal heat pumps, underfloor radiantheating and cooling, solar chimney, rainwater harvesting, a waterpurifier system, etc. The lab provides a carefully controlledenvironment to conduct research projects on building energy savings aswell as building energy harvests by various renewable energy sources(i.e., solar, wind, geothermal, etc.).

A pilot scale bioproducts manufacturing lab was also constructed. Thislab has a pilot scale compression molding processing line for both matforming and the lamination processes. It also has two extrusion systems,which are able to extrude samples both in large and small scales. Vacuumassist resin transfer molding process, reactor for nanoparticlesynthesis, sonication system for nanoparticle dispersion, box and tubevacuum furnaces for high temperature processing, etc. have beenimplemented in the bioproduct manufacturing laboratory.

Example 5

In yet another non-limiting example, the use of biomass (woody core fromkenaf or hemp) for building envelope insulation materials isdemonstrated to reduce the costs and the negative impact on theenvironment. Woody core and the PCM employed (paraffin wax) are bothhydrophobic, and are compatible with each other. The system used a smallamount of resin with the PCMs and a soy based thin film to enclose thePCM impregnated woody core to address the issue of PCM leaching atelevated temperature. The simulation approach provides the relationshipbetween the building energy savings and “effective” R-value of theinsulation materials.

The thermal properties for the composite materials include the thermalconductivity, specific heat, latent heat of fusion, and degree of PCMfilling for a small amount of composite materials. The thermalconductivity is analyzed at a Hot Disk Thermal Constants Analyzer forboth infiltrated and non-infiltrated samples. The sample size for thehot disk analyzer was around 2″ (Width)×2″ (Length)×1″ (Thickness). Thehot disk analyzer uses the transient heat conduction method tocharacterize the directional thermal conductivities of samples. Thespecific heat and latent heat of fusion of the PCM infiltratedcomposites is measured using the differential scanning calorimetry (DSC)instrument. The amount of sample required for the DSC measurement isonly ˜5 mg. Moreover, the open porosities of the biodegradable samplebefore and after the infiltration were measured by a Pycnometer throughgas penetration, and therefore, to determine the degree of filling ofPCM in the porous medium. Multiple samples were collected from the samepanel for the open porosity measurement to validate whether theinfiltration was uniformly distributed in the panel or not.

FIG. 13 . is a sketch of the heat transfer test section for the SIP. Thethermal conductivities of the porous biodegradable material before andafter infiltration are not expected to have a remarkable difference. ThePCM may or may not significantly affect the instinctive thermalconductivity of the bio-product. Moreover, the PCM may or may not beuniformly distributed in the porous medium, and the corresponding latentheat of fusion of the PCM-enhanced composite is expected to be more than65% of the pure PCM latent heat based on the optimum infiltrationprocess.

Large-scale characterization was conducted for the fabricated woodycore/PCM composite panel to demonstrate the composite thermal propertiesin large-scale panel. The transient heat conduction approach was appliedto the panel to verify the thermal properties in the bulk panelstructure. FIG. 13 shows the sketch of the heat transfer test section.The temperatures at various locations and surface of the panel weremeasured by the embedded thermocouples and infrared (IR) camera duringthe heating process. The measurement data was compared with thenumerical simulation results for the test section. Through matching thetemperature profiles, the actual thermal properties of the panel wereobtained.

For the expected results, the thermal properties, e.g., thermalconductivity (related to “actual” R-values), specific heat and latentheat of fusion (related to “effective” R-values), for the large-scalecomposite-based panel were determined, which provides the informationfor the building energy saving simulations. Moreover, the propertiesfrom large-scale characterization were expected to be close to thoseobtained from the small-scale samples.

Modeling and simulations were used to predict the building energysavings by using the woody core biomass/PCM composite insulation. Thebuilding energy savings may be calculated through building energymodeling. The EnergyPlus program can be used to predict the potentialenergy savings in the aforementioned lab example when replacing one sideof the wall with the fabricated PCM-enhanced biomass based SIP. The labexample was designed into three zones in the EnergyPlus model:Mechanical Room, Electrical Room, and Conditioned Zone. The program canbe set up to provide the heating and cooling load output for each zonein the building. The occupant schedule, wall constructions, materialproperties, and building location were input in the model. Furthermore,the temperature and airflow distributions in the lab example can besimulated through commercial software ANSYS Fluent (available fromANSYS®) or COMSOL Multiphysics (available from COMSOL Multiphysics®).

The building energy savings as well as building temperature and airflowdistributions are obtained and the annual lab example building heatingand cooling power consumptions have a range of up to 30-40% when usingthe optimized biodegradable material/PCM SIP in the wall structure.Moreover, the location of PCM in the wall structure is also important.

Example 6 Correlation to Calculate “Effective” R-Value for PCM-EnhancedInsulation

Through the thermal properties characterization, numerical simulations,and building energy modeling, metrics were developed to study theparametric effects on the building energy savings and “effective”R-values. Table 3 displays the variations of building energy savingswith respect to the pore size and open porosity, PCM degree of filling,thermal conductivity, specific heat and latent heat of fusion ofcomposite, the positions of woody core-PCM composite based SIP in thebuilding envelope, and building wall inner and outer surfacetemperatures. The “actual” R-value (R_(act)) of the SIP is calculatedbased on its thermal conductivity:

$\begin{matrix}{R_{act} = {{thickness}\mspace{14mu}{of}\mspace{14mu}{{SIP}/{apparent}}\mspace{14mu}{thermal}\mspace{14mu}{conductivity}}} & {{Eq}.\mspace{14mu}(1)}\end{matrix}$

The “effective” R is evaluated based on the building energy savings andwall inner surface temperatures. The thermal inertia takes the latentheat of fusion into consideration. The “effective” R-value is determinedby the “actual” R-value of non-PCM SIP under the same energy saving andwall inner surface temperature situation. The “effective” R-value isexpected to be higher than the “actual” R-value of the material toinclude the latent heat effect.

TABLE 3 Metrics for the development of “effective” R-value forPCM-embedded SIP. (Metrics 1) Position Wall Pore size PCM of PCM- innerand open degree of Thermal enhanced surface Energy “actual” “effective”porosity filling^(#) properties SIP temp. consum. R-value R-value Non-A₁ — C₁ (No D₁ E₁ F₁ R_(act-1) — PCM latent heat) SIP* SIP A₂ < A₁ ≥65%C₂ (latent D₂ = D₁ E₂ < E₁ F₂ < F₁ R_(act-2)≈ R_(eff-2) > R_(act-2) withheat of (reduced R_(act-1) (i.e., R_(eff-2)≥ PCM fusion) by 30- 10 perinch) 40%)^(&) *The control group ^(#)PCM degree of filling (%) =^(&)The annual ZØE lab energy consumptions are expected to be reduced byup to 30-40% when using PCM in SIP.

The “effective” R-values for PCM-embedded panels is calculated accordingto a correlation described by the function of a series of parameters,including pore size and open porosity, PCM degree of filling, and the“actual” R-value of the biodegradable insulation. The “effective”R-value of the PCM-enhanced biodegradable insulation is expected toachieve a value of greater than or equal to 10 per inch-thickness.

The fabricated SIP is integrated in the wall structure of the lab toexperimentally test the effect of woody core/PCM composite based SIPs onoverall building energy savings. The energy consumptions of variousdevices and equipment in the lab is collected daily. The lab separatesthe electricity readings for different types of electricity consumptiondevices, including the HVAC system, lighting, solar control panel, etc.with the focus on the HVAC system energy savings. Furthermore, the labincludes sub-metering capabilities to demonstrate the performance of thebuilding system. Multiple thermal sensors and airflow meters are placedat different elevations in the lab to get the whole temperaturedistribution and airflow field. The collected HVAC electricityconsumptions, measured lab temperature and airflow fields are comparedwith the simulation results to validate.

The purpose of the field-testing is to verify the building energymodeling, the evaluated “effective” R-values for the woody core/PCMcomposite based SIP in the previous task, and demonstrate thefeasibility of the proposed PCM-enhanced biodegradable insulation forbuilding application.

The comparison metrics for the experimental measurements and simulationresults (shown in Table 4) are generated to demonstrate the predictionmodels and correlations developed in the previous examples. BothPCM-enhanced and non-PCM biodegradable insulations are experimentallytested in the lab building envelope to demonstrate the energy savings bythe PCM. The simulation results expect within +15% variation of themeasurement data under the same situation. Three to five panels arefabricated and tested for each case (e.g., insulations with/without PCMembedded) to obtain more reliable measurement data. It is expected thatabove 90% of the tests are within ±15% variation of the simulationresult. Through the numerical and experimental investigations, thedegree of building energy savings using biomass/PCM composite insulationcan be quantitatively determined based on the building size, localweather conditions, and PCM thermal properties.

TABLE 4 Comparison metrics for the experimental measurements andsimulation results of the ZØE lab performances. (Metrics 2) EnergyBuilding Building consumptions temperature airflow of the HVACdistribution field system R-value* Experimental Insulation T₁₋₁ V₁₋₁E₁₋₁ R₁₋₁ measurements without PCM PCM-enhanced T₁₋₂ V₁₋₂ E₁₋₂ < E₁₋₁R₁₋₂ ≈ R₁₋₁ insulation Simulation Insulation T₂₋₁ V₂₋₁ E₂₋₁ R₂₋₁ resultswithout PCM PCM-enhanced T₂₋₂ V₂₋₂ E₂₋₂ < E₂₋₁ R₂₋₂ (≥10 insulation perinch) *R₁₋₁, R₁₋₂ and R₂₋₁ are the “actual” R-values of the insulation.R₁₋₂ is expected to be close to the value of R₁₋₁, to demonstrate thatthe infiltrated PCM will not significantly alter the instinctive R-valueof biodegradable insulation. R₂₋₂ is the “effective” R-value input inthe building energy modeling to simulate the phase-changing effect; R₂₋₂is expected to be higher than the other three “actual” values to matchwith the reduced energy consumption results (E₂₋₂).

Example 7 Life Cycle Analyses for the SIP Wall from Woody CoreBiomass/PCM Composite Insulation

Life Cycle Analysis (LCA) may include three components: life cyclecumulative energy demand assessment (LC-CED) focusing on the totalenergy demand in life cycle; LCA on environmental impacts, and lifecycle costing (LCC) on economic impacts. The LCA framework methodologyprovided by the International standard organization (ISO) 14040 (ISO2006) is utilized to assess comprehensive impacts of LCA, LCC and LC-CEDfor the proposed PMC impregnation process. The commercial SimaPro 8.2.3software is used for the evaluation.

The system boundaries considered in the project consists of PCMtreatment process. The LCA system boundary including the basic LCAmaterial. The input items for LCA are energy, materials, machinery andlabor; while the output includes energy consumed, which will be thesystem boundary under consideration. The “cradle-to-grave impacts”function is used, which means that the system boundary is consideredwhen the cellulose is received from the treatment system, in thepressure reactor, processed into insulation, used in buildingconstruction, and ends with the disposal. The functional unit ofproposed project is one 200 square foot house with working life of 50years.

For a wide assessment of environmental impact, the Building forEnvironmental and Economic Sustainability impact set and Eco-indicator99 (burden on environment) may be used. Three types of environmentaldamages may be considered: Human health, Ecosystem quality, and Resourcedepletion. These damages are quantified by damage models. The BEEStechnology has a recognized and accepted methodology to ensure a levelplaying field. The global warming potential (GWP) used by BEES wasdeveloped in 2001 by the International Panel on climate change.

The data collection is performed during the operation of the system forrepetitive times. The operational inputs and quantity of insulation maybe measured at different times of the year. The data to be collectedinclude:

Data for LCA: GHG emissions: quantities of all materials andcorresponding life cycle inventory data. The life cycle inventory datawill be obtained from existing software packages (SimaPro) or opendatabase (such as US LCI database).

Data for LCC: Economic present values: material costs, maintenance andretrofitting costs and residual values of envelope materials. R.S. Meansmay be used for most of the material costs, as well as maintenance andretrofitting costs. Surveys will be performed to collected additionalcosts for all costs and residual values of the selected materials.

Data for LC-CED: Total energy demand data related to life cycle.

The LCA results show that the SIP wall from the biomass/PCM compositeinsulation provides a significant contribution to the energy efficiencyof the building construction, where significant may range from 5% to300% improved energy efficiency compared to synthetic fiber insulationmaterials. In addition, the improved energy efficiency may include arange from 5%-8%, from 5%-20%, from 5%-50%, from 20%-75%, from 50%-150%,from at least 5%, from at least 10%, and from at least 20% energyefficiency. Compared to the synthetic fiber insulation materials, thewoody core biomass/PCM presents advantage for the environmental and costbenefit.

Having described various systems and methods herein, certain embodimentscan include, but are not limited to:

In a first embodiment, an insulated material comprises: an porousmaterial, wherein the porous material comprises a plurality of pores;and a phase change material disposed within the plurality of pores inthe porous material.

A second embodiment can include the insulated material of the firstembodiment, further comprising: a binder, wherein the binder is mixedwith the phase change material within the plurality of pores.

A third embodiment can include the insulated material of the secondembodiment, wherein the binder comprises a material selected from thegroup consisting of: epoxy resin, phenoxy resin, alkyd resin, acrylicresin, vinyl resin, polyester resin, polyurethane resin, Vinylacetate/ethylene copolymer emulsion, high solids epoxy, amine-curedepoxy, water-based latex, two-part epoxy, and mixtures thereof.

A fourth embodiment can include the insulated material of any one of thefirst to third embodiments, further comprising: a thin film disposed onat least one outside surface of the porous material.

A fifth embodiment can include the insulated material of any one of thefirst to fourth embodiments, wherein the porous material comprises amaterial selected from the group consisting of: a porous biomass, aporous polymer, a porous lignocellulosic fiber, a porous polyurethanefoam, a porous expanded polystyrene, a porous air-entrained concrete, aporous rock wool, a porous polyisocyanurate material, a porous naturalplant material, a partially delignified lignocellulosic biomass, andcombinations thereof.

A sixth embodiment can include the insulated material of any one of thefirst to fifth embodiments, wherein the phase change material comprisesa material selected from the group consisting of: 1-dodecanol,n-octadecane, polyethylene glycol 900, 1-tetradecanol, medicinalparaffin, a paraffin wax, paraffin RT60/RT58, biphenyl, CaCl₂.6H₂O,Na₂SO₄.10H₂O, Na₂CO₃.10H₂O, capric acid, lauric acid, myristic acid,palmitic acid, stearic acid, and combinations thereof.

A seventh embodiment can include the insulated material of any one ofthe first to fifth embodiments, wherein the phase change materialcomprises a material selected from the group consisting of: LiClO₃.3H₂O,ZnCl₂.3H₂O, a eutectic water-salt solution: 22.4-23.3 wt. % NaClsolution, Paraffin C14, Paraffin C15-C16, Polyglycol E400, Formic acid,propyl pamiate, isopropyl pamiate, a salt solution, and combinationsthereof.

An eighth embodiment can include the insulated material of any one ofthe first to seventh embodiments, further comprising: one or moreinsulated panels, wherein the porous material is disposed on a surfaceof the one or more insulated panels.

A ninth embodiment can include the insulated material of any one of thefirst to eighth embodiments, wherein a mass ratio of the phase changematerial to the porous material is between 10:1 to 1:10.

A tenth embodiment can include the insulated material of any one of thefirst to ninth embodiments, wherein the phase change material isencapsulated in an encapsulant, and wherein the phase change material isdisposed in the plurality of pores in the encapsulant.

An eleventh embodiment can include the insulated material of any one ofthe first to tenth embodiments, further comprising: a flame retardant,wherein the flame retardant is disposed on the porous material.

In a twelfth embodiment, an insulation system comprises: a container;and a phase change material disposed within the container.

A thirteenth embodiment can include the insulation system of the twelfthembodiment, wherein the container has a rectilinear configuration havinga thickness in a range of 0.25 inches to 10 inches.

A fourteenth embodiment can include the insulation system of the twelfthembodiment, wherein the container comprises a plurality of pipes,wherein the phase change material is disposed in the plurality of pipes.

A fifteenth embodiment can include the insulation system of thefourteenth embodiment, wherein the plurality of pipes are arranged in arow.

A sixteenth embodiment can include the insulation system of any one ofthe twelfth to fifteenth embodiments, further comprising: one or moreinsulation layers, wherein the one or more insulation layers are coupledto the container.

A seventeenth embodiment can include the insulation system of any one ofthe twelfth to sixteenth embodiments, further comprising: a thin filmdisposed on at least one outside surface of the porous material.

An eighteenth embodiment can include the insulation system of any one ofthe twelfth to seventeenth embodiments, wherein the porous materialcomprises a material selected from the group consisting of a porousbiomass, a porous polymer, a porous lignocellulosic fiber, a porouspolyurethane foam, a porous expanded polystyrene, a porous air-entrainedconcrete, a porous rock wool, a porous polyisocyanurate material, aporous natural plant material, a partially delignified lignocellulosicbiomass, and combinations thereof.

A nineteenth embodiment can include the insulation system of any one ofthe twelfth to seventeenth embodiments, wherein the phase changematerial comprises a material selected from the group consisting of1-dodecanol, n-octadecane, polyethylene glycol 900, 1-tetradecanol,medicinal paraffin, a paraffin wax, paraffin RT60/RT58, biphenyl,CaCl₂·6H₂O, Na₂SO₄·10H₂O, Na₂CO₃·10H₂O, capric acid, lauric acid,myristic acid, palmitic acid, stearic acid, and combinations thereof.

A twentieth embodiment can include the insulation system of any one ofthe twelfth to seventeenth embodiments, wherein the phase changematerial comprises a material selected from the group consisting of:LiClO₃·3H₂O, ZnCl₂·3H₂O, a eutectic water-salt solution: 22.4-23.3 wt. %NaCl solution, Paraffin C14, Paraffin C15-C16, Polyglycol E400, Formicacid, propyl pamiate, isopropyl pamiate, a salt solution, andcombinations thereof.

In a twenty first embodiment, a method of making an insulated materialcomprises: melting a phase change material to form liquid phase changematerial; combining the liquid phase change material with an insulatingmaterial; and forming a composite insulation material in response to thecombining.

A twenty second embodiment can include the method of the twenty firstembodiment, wherein the insulating material is a porous material,wherein the porous material comprises a plurality of pores, and whereinthe liquid phase change material is disposed in the plurality of pores.

A twenty third embodiment can include the method of the twenty secondembodiment, further comprising: mixing a binder with the liquid phasechange material prior to combining the liquid phase change material withthe porous material.

A twenty fourth embodiment can include the method of the twenty secondembodiment, wherein the binder comprises a material selected from thegroup consisting of epoxy resin, phenoxy resin, alkyd resin, acrylicresin, vinyl resin, polyester resin, polyurethane resin, Vinylacetate/ethylene copolymer emulsion, high solids epoxy, amine-curedepoxy, water-based latex, two-part epoxy, and mixtures thereof.

A twenty fifth embodiment can include the method of the twenty firstembodiment, wherein the liquid phase change material is contained in anencapsulant, and wherein combining the liquid phase change material withthe insulating material comprises: mixing the liquid phase changematerial in the encapsulant into the insulating material.

A twenty sixth embodiment can include the method of the twenty firstembodiment, wherein the phase change material is disposed in acontainer, and wherein the combining the liquid phase change materialwith the insulating material comprises coupling the container to theinsulating material.

A twenty seventh embodiment can include the method of any one of thetwenty first to twenty sixth embodiments, further comprising: forming apanel from the insulated material.

A twenty eighth embodiment can include the method of the twenty seventhembodiment, further comprising: disposing a film on at least one surfaceof the panel.

A twenty ninth embodiment can include the method of any one of thetwenty first to twenty eighth embodiments, wherein the porous materialcomprises a material selected from the group consisting of: a porousbiomass, a porous polymer, a porous lignocellulosic fiber, a porouspolyurethane foam, a porous expanded polystyrene, a porous air-entrainedconcrete, a porous rock wool, a porous polyisocyanurate material, aporous natural plant material, a partially delignified lignocellulosicbiomass, and combinations thereof.

A thirtieth embodiment can include the method of any one of the twentyfirst to twenty ninth embodiments, wherein the phase change materialcomprises a material selected from the group consisting of: 1-dodecanol,n-octadecane, polyethylene glycol 900, 1-tetradecanol, medicinalparaffin, a paraffin wax, paraffin RT60/RT58, biphenyl, CaCl₂·6H₂O,Na₂SO₄·10H₂O, Na₂CO₃·10H₂O, capric acid, lauric acid, myristic acid,palmitic acid, stearic acid, and combinations thereof.

A thirty first embodiment can include the method of any one of thetwenty first to thirtieth embodiments, wherein melting the phase changematerial comprises raising the temperature of the phase change materialto between about 2-10° C. above a melting temperature of the phasechange material.

A thirty second embodiment can include the method of any one of thetwenty first to thirty first embodiments, wherein a mass ratio of thephase change material to the porous material is between 1:10 and 10:1.

A thirty third embodiment can include the method of any one of thetwenty first to thirty second embodiments, wherein disposing the liquidphase change material into the plurality of pores comprises:pressurizing the liquid phase change material and the porous material ina vessel; and holding the pressure to dispose the liquid phase changematerial into the plurality of pores.

A thirty fourth embodiment can include the method of the thirty thirdembodiment, wherein the vessel is pressurized to 100 psia or greater.

In a thirty fifth embodiment, an insulated panel comprises: aninsulation layer; and an composite insulation material disposed on atleast one surface of the insulation layer, wherein the compositeinsulation material comprises a phase change material.

A thirty sixth embodiment can include the insulated panel of the thirtyfifth embodiment, further comprising: a film disposed on at least onesurface of the porous material, wherein the film is configured to sealthe at least one surface of the porous material.

A thirty seventh embodiment can include the insulated panel of thethirty fifth or thirty sixth embodiment, wherein an edge of theinsulated panel is configured to interlock with an adjacent insulatedpanel.

A thirty eighth embodiment can include the insulated panel of any one ofthe thirty fifth to thirty seventh embodiments, wherein a height andwidth of the insulated panel are in a range of from about 3 feet toabout 12 feet.

A thirty ninth embodiment can include the insulated panel of any one ofthe thirty fifth to thirty eighth embodiments, wherein a thickness ofthe insulated panel is in a range of between about 0.25 inches to about24 inches.

A fortieth embodiment can include the insulated panel of any one of thethirty fifth to thirty ninth embodiments, further comprising: a conduitdisposed through the insulated panel.

A forty first embodiment can include the insulated panel of any one ofthe thirty fifth to fortieth embodiments, further comprising a secondinsulation layer, wherein the porous material is disposed between theinsulation layer and the second insulation layer.

A forty second embodiment can include the insulated panel of any one ofthe thirty fifth to forty first embodiments, further comprising: areinforcing support, wherein the reinforcing support comprises at leastone of rebar, a long fiber, or a conduit.

A forty third embodiment can include the insulated panel of any one ofthe thirty fifth to forty second embodiments, further comprising: ametal facing layer disposed on the insulation layer.

A forty fourth embodiment can include the insulated panel of the fortythird embodiment, wherein the metal facing layer has a thickness betweenabout 10 microns and about 8 mm.

A forty fifth embodiment can include the insulated panel of any one ofthe thirty fifth to forty fourth embodiments, further comprising: anintumescent coating configured to provide fire resistance to theinsulated panel.

A forty sixth embodiment can include the insulated panel of any one ofthe thirty fifth to forty fifth embodiments, wherein the insulated panelis configured to be used as insulation for a refrigerated compartment.

A forty seventh embodiment can include the insulated panel of any one ofthe thirty fifth to forty sixth embodiments, wherein the porous materialcomprises a material selected from the group consisting of a porousbiomass, a porous polymer, a porous lignocellulosic fiber, a porouspolyurethane foam, a porous expanded polystyrene, a porous air-entrainedconcrete, a porous rock wool, a porous polyisocyanurate material, aporous natural plant material, a partially delignified lignocellulosicbiomass, and combinations thereof.

A forty eighth embodiment can include the insulated panel of any one ofthe thirty fifth to forty seventh embodiments, wherein the phase changematerial comprises a material selected from the group consisting of1-dodecanol, n-octadecane, polyethylene glycol 900, 1-tetradecanol,medicinal paraffin, a paraffin wax, paraffin RT60/RT58, biphenyl,CaCl₂·6H₂O, Na₂SO₄·10H₂O, Na₂CO₃·10H₂O, capric acid, lauric acid,myristic acid, palmitic acid, stearic acid, and combinations thereof.

In a forty ninth embodiment, a method of providing insulation comprises:heating a first side of a composite insulation material, wherein thecomposite insulation material comprises the first side and a secondside, wherein the composite insulation material comprises: a phasechange material; melting at least a portion of the phase change materialin response to the heating; and reducing heat transmission through thecomposite insulation material from the first side to the second sidebased on the melting.

A fiftieth embodiment can include the method of the forty ninthembodiment, further comprising: reducing the temperature on the firstside of the composite insulation material; and solidifying the phasechange material in response to reducing the temperature on the firstside of the composite insulation material.

A fifty first embodiment can include the method of the forty ninth orfiftieth embodiment, wherein the insulated material further comprises: abinder, wherein the binder is mixed with the phase change material anddisposed within a plurality of pores in a porous material.

A fifty second embodiment can include the method of the fifty firstembodiment, wherein the binder comprises a material selected from thegroup consisting of: epoxy resin, phenoxy resin, alkyd resin, acrylicresin, vinyl resin, polyester resin, polyurethane resin, Vinylacetate/ethylene copolymer emulsion, high solids epoxy, amine-curedepoxy, water-based latex, two-part epoxy, and mixtures thereof.

A fifty third embodiment can include the method of any one of the fortyninth to fifty second embodiments, wherein the composite insulationmaterial further comprises: a thin film disposed on at least one outsidesurface of the composite insulation material.

A fifty fourth embodiment can include the method of the fifty thirdembodiment, further comprising: retaining the phase change material inthe composite insulation material when at least the portion of the phasechange material is melted using the thing film.

A fifty fifth embodiment can include the method of any one of the fortyninth to fifty fourth embodiments, wherein the composite insulationmaterial comprises a material selected from the group consisting of: aporous biomass, a porous polymer, a porous lignocellulosic fiber, aporous polyurethane foam, a porous expanded polystyrene, a porousair-entrained concrete, a porous rock wool, a porous polyisocyanuratematerial, a porous natural plant material, a partially delignifiedlignocellulosic biomass, and combinations thereof.

A fifty sixth embodiment can include the method of any one of the fortyninth to fifty fifth embodiments, wherein the phase change materialcomprises a material selected from the group consisting of: 1-dodecanol,n-octadecane, polyethylene glycol 900, 1-tetradecanol, medicinalparaffin, a paraffin wax, paraffin RT60/RT58, biphenyl, CaCl₂·6H₂O,Na₂SO₄·10H₂O, Na₂CO₃·10H₂O, capric acid, lauric acid, myristic acid,palmitic acid, stearic acid, and combinations thereof.

A fifty seventh embodiment can include the method of any one of theforty ninth to fifty sixth embodiments, further comprising: one or moreinsulated panels coupled to the composite insulation material.

A fifty eighth embodiment can include the method of any one of the fortyninth to fifty seventh embodiments, wherein composite insulationmaterial is a layer in a wall of a refrigeration compartment, whereinthe first side faces an exterior of the refrigeration compartment, andwherein the second side faces an interior of the refrigerationcompartment.

Embodiments are discussed herein with reference to the Figures. However,those skilled in the art will readily appreciate that the detaileddescription given herein with respect to these figures is forexplanatory purposes as the systems and methods extend beyond theselimited embodiments. For example, it should be appreciated that thoseskilled in the art will, in light of the teachings of the presentdescription, recognize a multiplicity of alternate and suitableapproaches, depending upon the needs of the particular application, toimplement the functionality of any given detail described herein, beyondthe particular implementation choices in the following embodimentsdescribed and shown. That is, there are numerous modifications andvariations that are too numerous to be listed but that all fit withinthe scope of the present description. Also, singular words should beread as plural and vice versa and masculine as feminine and vice versa,where appropriate, and alternative embodiments do not necessarily implythat the two are mutually exclusive.

It is to be further understood that the present description is notlimited to the particular methodology, compounds, materials,manufacturing techniques, uses, and applications, described herein, asthese may vary. It is also to be understood that the terminology usedherein is used for the purpose of describing particular embodimentsonly, and is not intended to limit the scope of the present systems andmethods. It must be noted that as used herein and in the appended claims(in this application, or any derived applications thereof), the singularforms “a,” “an,” and “the” include the plural reference unless thecontext clearly dictates otherwise. Thus, for example, a reference to“an element” is a reference to one or more elements and includesequivalents thereof known to those skilled in the art. All conjunctionsused are to be understood in the most inclusive sense possible. Thus,the word “or” should be understood as having the definition of a logical“or” rather than that of a logical “exclusive or” unless the contextclearly necessitates otherwise. Structures described herein are to beunderstood also to refer to functional equivalents of such structures.Language that may be construed to express approximation should be sounderstood unless the context clearly dictates otherwise.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meanings as commonly understood by one of ordinary skillin the art to which this description belongs. Preferred methods,techniques, devices, and materials are described, although any methods,techniques, devices, or materials similar or equivalent to thosedescribed herein may be used in the practice or testing of the presentsystems and methods. Structures described herein are to be understoodalso to refer to functional equivalents of such structures. The presentsystems and methods will now be described in detail with reference toembodiments thereof as illustrated in the accompanying drawings.

From reading the present disclosure, other variations and modificationswill be apparent to persons skilled in the art. Such variations andmodifications may involve equivalent and other features which arealready known in the art, and which may be used instead of or inaddition to features already described herein.

Although claims may be formulated in this application or of any furtherapplication derived therefrom, to particular combinations of features,it should be understood that the scope of the disclosure also includesany novel feature or any novel combination of features disclosed hereineither explicitly or implicitly or any generalization thereof, whetheror not it relates to the same systems or methods as presently claimed inany claim and whether or not it mitigates any or all of the sametechnical problems as do the present systems and methods.

Features which are described in the context of separate embodiments mayalso be provided in combination in a single embodiment. Conversely,various features which are, for brevity, described in the context of asingle embodiment, may also be provided separately or in any suitablesub-combination. The Applicant(s) hereby give notice that new claims maybe formulated to such features and/or combinations of such featuresduring the prosecution of the present Application or of any furtherApplication derived therefrom.

What is claimed is:
 1. An insulation system comprising: a porousmaterial; a container; a composite insulation material including a phasechange material disposed within the container and the porous material,wherein the container is formed in the porous material and is made outof the porous material; one or more insulation layers, wherein the oneor more insulation layers are coupled to the container and the compositeinsulation material; and a film disposed on at least one surface of theporous material, wherein the film is configured to seal the at least onesurface of the porous material.
 2. The insulation system of claim 1,wherein the container has a rectilinear configuration having a thicknessin a range of 0.25 inches to 10 inches.
 3. The insulation system ofclaim 1, wherein the film comprises a polymeric film or a biobased film.4. The insulation system of claim 1, wherein the porous materialcomprises a material selected from the group consisting of: a porousbiomass, a porous polymer, a porous lignocellulosic fiber, a porouspolyurethane foam, a porous expanded polystyrene, a porous air-entrainedconcrete, a porous rock wool, a porous polyisocyanurate material, aporous natural plant material, a partially delignified lignocellulosicbiomass, and combinations thereof.
 5. The insulation system of claim 1,wherein the phase change material comprises a material selected from thegroup consisting of: 1-dodecanol, n-octadecane, polyethylene glycol 900,1-tetradecanol, medicinal paraffin, a paraffin wax, paraffin RT60/RT58,biphenyl, CaCl₂·6H₂O, Na₂SO₄·10H₂O, Na₂CO₃·10H₂O, capric acid, lauricacid, myristic acid, palmitic acid, stearic acid, and combinationsthereof.
 6. The insulation system of claim 1, wherein the phase changematerial comprises a material selected from the group consisting of:LiClO₃·3H₂O, ZnCl₂·3H₂O, a eutectic water-salt solution: 22.4-23.3 wt. %NaCl solution, Paraffin C14, Paraffin C15-C16, Polyglycol E400, Formicacid, propyl pamiate, isopropyl pamiate, a salt solution, andcombinations thereof.
 7. The insulation system of claim 1, wherein thecontainer further comprises a plurality of pipes, wherein a portion ofthe phase change material is disposed in the plurality of pipes.
 8. Theinsulation system of claim 7, wherein the pluralities of pipes arearranged in a row.
 9. An insulated panel comprising: a container; aninsulation layer; and a composite insulation material disposed on atleast one surface of the insulation layer, wherein the compositeinsulation material comprises a porous material and a phase changematerial, wherein the phase change material is disposed within thecontainer, and wherein the container is formed in the porous materialand is made out of the porous material; and a film disposed on at leastone surface of the composite insulation material, wherein the film isconfigured to seal the at least one surface of the composite insulationmaterial.
 10. The insulated panel of claim 9, wherein the porousmaterial comprises PVC, honeycomb, plastic, stainless steel, andaluminum panels.
 11. The insulated panel of claim 9, wherein an edge ofthe insulated panel is configured to interlock with an adjacentinsulated panel.
 12. The insulated panel of claim 9, wherein a heightand width of the insulated panel are in a range of from about 3 feet toabout 12 feet.
 13. The insulated panel of claim 9, wherein a thicknessof the insulated panel is in a range of between about 0.25 inches toabout 24 inches.
 14. The insulated panel of claim 9, further comprising:a conduit disposed through the insulated panel.
 15. The insulated panelof claim 9, further comprising: a second insulation layer, wherein thecomposite insulation material is disposed between the insulation layerand the second insulation layer.
 16. The insulated panel of claim 9,further comprising: a reinforcing support, wherein the reinforcingsupport comprises at least one rebar, a long fiber, or a conduit. 17.The insulated panel of claim 9, further comprising: an intumescentcoating disposed on at least one of the insulation layer or thecomposite insulation material, wherein the intumescent coating isconfigured to provide fire resistance to the insulated panel.
 18. Theinsulated panel of claim 9, wherein the insulated panel is configured tobe used as insulation for a refrigerated compartment or a house.
 19. Theinsulated panel of claim 9, further comprising: a metal facing layercoupled to the composite insulation material.
 20. The insulated panel ofclaim 19, wherein the composite insulation material comprises: aplurality of said insulation layers, wherein the plurality of insulationlayers are coupled to the composite insulation material.